Method of making rigid polyurethane foams

ABSTRACT

AN IMPROVED PROCESS OF MAKING RIGID POLYURETHANE FOAMS IS DISCLOSED WHICH COMPRISES INCORPORATING THEREIN NEW SILOXANE-POLYETHYLENE OXIDE COPOLYMERS. WITH THIS PROCESS IT IS POSSIBLE TO CONSISTENTLY PRODUCE UNIFORM FINECELLED FOAMS HAVING A HIGH PERCENTAGE OF CLOSED CELLS UNDER A WIDE VARIETY OF MANUFACTURING CONDITIONS.

United States Patent Int. Cl. C08g 22/44 The portion of the term of the patent subsequent to Aug. 20, 1985, has been disclaimed US. Cl. 2602.5 AM 7 Claims ABSTRACT OF THE DISCLOSURE An improved process of making rigid polyurethane foams is disclosed which comprises incorporating therein new siloxane-polyethylene oxide copolymers. With this process it is possible to consistently produce uniform finecelled foams having a high percentage of closed cells under a wide variety of manufacturing conditions.

This application is a division of application Ser. No. 546,548, filed May 2, 1966 now U.S. Pat. 3,518,288.

One of the fastest growing industries in recent decades has been the one directed to products made from foamed materials. These foam products have found many diverse uses such as in filters for cigarettes, filters for air-conditioning systems, fuel filters, thermal and cryogenic insulations, sound insulation, structural and dimensional supports, laminated structures, protective packaging for fragile items, candle holders, bases for table decorations (center pieces), Christmas tree ornaments and toys. The foamed products are generally identified as being either of the flexible or rigid type, and can be of any of the basic chemical classes of foams well known in the art. Not only does each chemical class of foam have its own peculiar problem, but also each type of foam (flexible or rigid) within that class has it own problems. To further complicate the picture, the particular intended utility of the foam usually demands some special considerations too.

As was pointed out above, this invention is directed to polyurethane foams of the rigid type. It is an object of this invention to provide an improved method for making rigid polyurethane foams. Another object is to provide an additive useful for making rigid polyurethane foams. Still another object of this invention to provide an additive and method whereby it is possible to consistently produce uniform, fine-celled rigid polyurethane foams having a high percentage of closed cells under a wide variety of manufacturing conditions. It is a further object to provide an additive and method for making rigid polyurethane foams adaptable to a wide range of foaming conditions and foaming systems, including both one-shot and prepolymer systems. Yet another object is to provide an additive and method for making rigid polyurethane foams which are superior for foamed-in-place applications by virtue of excellent flowability. Other advantages of the additive and method of this invention include hydrolytic and chemical stability in storage or mixtures with most systems; improved compatibility with foam ingredients including additives such as viscosity stabilizers and flame retardants; improved miscibility through greater retention of fluorocarbon blowing agents in mixes; and handling ease including desirable low viscosity ideal for production equipment. Other objects and advantages of this invention will be apparent from the following detailed description.

More specifically, this invention relates to an improvement in a method of making a rigid polyurethane foam which includes mixing together a polymer selected from the group consisting of hydroxylated polyesters and hydroxylated polyethers, an organic polyisocyanate, a catalyst and a blowing agent, the improvement comprising incorporating therein a compound selected from the group consisting of siloxanes having the average structural formulae in which formulae R is a hydrocarbon radical free of aliphatic unsaturation and contains from 1 to 10 carbon atoms, A is a radical of the structure -D(OC H ),G wherein D is an alkylene radical, G is a radical selected from the group consisting of the 0 o o -odR, -0doR and -0dNHR radicals wherein R is as defined above, 1 has an average value from 9 to 30, a has an average value from 0 to 1, b has an average value from 6 to 192, c has an average value from 0 to 30, d has an average value from 3 to 30, and g has an average value from 1 to 30, the ratio of the OSi(CH units to the OSi(CH )A and/or OSi(CH A units in the siloxane being in the range of 2:1 to 6: 1.

This invention further relates to an additive for making improved rigid polyurethane foams which is a compound selected from the group consisting of siloxanes having the average structural formulae and 3)3 3)albbosi( a) ]d a)3 in which formulae R is a hydrocarbon radical free of aliphatic unsaturation and contains from 1 to 10 carbon atoms, A is a radical of the structure -D(OC H.,),G wherein D is an alkylene radical, G is a radical selected from the group consisting of the o o 0 oi LR, O(UJOR and -o dNHR radicals wherein R is as defined above, 1 has an average value from 9 to 30, a has an average value from 0 to 1, b has an average value from 6 to 192, c has an average value from 0 to 30, d has an average value from 3 to 30, and e has an average value from 1 to 30, the ratio of the OSi(CH units to the OSi(CH )A and/or OSi(CH A units the siloxane being in the range of 2:1 to 6:1.

As is apparent from the above defined process, the hydroxylated materials and polyisocyanates which are reacted to form the urethane polymer, the catalyst for promoting the reaction, and the blowing agent for foaming the mixture, are all well known to those skilled in the art. Since these materials do not go to the essence of this invention, and since detailed listings and descriptions of them exist numerous places elsewhere, no further mention will be made of them here.

The siloxanes used in the above process, which constitute the additives of this invention, are new compounds. These siloxanes can be readily prepared by well-known methods. For example, they can be prepared by reacting the appropriate ESlH containing siloxane with the appropiate polyethylene glycol having a terminally unsaturated aliphatic group on one end and an appropriate capping group on the other end, the reaction being carried out in the presence of a platinum catalyst in a suitable 501- vent. While this type of reaction is generally well known CHFOHOHKO(M10120gNHCZH to those skilled in the art, the preparation of the siloxanes 5 of this invention will be illustrated in more detail in the 423 f mpropanol, 423 of toluene and 1 of a examples for the benefit of the tyros- 2% platinum (as chloroplatinic acid) solution in iso- The siloxanes that will achieve the objects of this inpropanol. The foregoing mixture was heated at 78 to 95 vention are relatively few as should be apparent from the C. for about 30 minutes, filtered, and then stripped to 149 formulae supra. Thus, with the exceptions of the R and A C. at 4 m. of mercury res Th od t,

groups, essentially all substituents on the silicon atoms h d a viscosity of 279 cs a r fr tiv index of 1 4499 must be methyl radicals. and a specific gravity of 1.079.

The R group in Formulae 1 and 2 can be any hydrocarbon radical free of aliphatic unsaturation which con- EXAMPLE 2 tains from 1 to 10 carbon atoms. For example, R can be h procedure f Example 1 was repeated except that an alkyl, cycloalkyl, aryl, alkaryl or an aralkyl radical. 3 4 f the Siloxane By way of illustration, R can be a methyl, ethyl, propyl, isopropyl, butyl, tertiary, butyl, amyl, hexyl, heptyl, octyl, nonyl, decyl, cyclopentyl, cyclohexyl, phenyl, naphthyl, tolyl, xylyl, mesityl, t-butylphenyl, benzyl, 2-phenylethyl or was used and the reaction was carried out at 85 to 110 C. a 2-phenylpropyl radical. The product,

The A radical in the above formulae must have the had a viscosity of 322 cs., a refractive index of 1.4487 and structure D(OC H G. In this structure D is any alkyla specific gravity of 1.067.

ene radical. For example, D can be a methylene, ethylene, 3O EXAMPLE 3 propylene, butylene, isobutylene, hexylene, octylene, dodecylene, octadecylene or a triacontylene radical. Pref- The of Example 1 was repeated except that erably, D contains from 3 to 18 carbon atoms. of the 5110x3118 In the structure of A, the G radical can be an acyloxy (CH Si[()Si(CI-I [OSi(CI-I )H] OSi(cI-I was used, 41.4 g. of the n-propanol and toluene was used, H the reaction was carried out at 90 to 99 C. and the mix- (-0CR) ture stripped to 151 C. at 5 mm. of pressure. The carbonate ester product,

(CH )3Sl[OSi(CHI)2]13[Osi(CH3)CH2CH CHz(OCzH4)1zO%NHC2H5]5OSl(CH3) had a viscosity of 545 cs., a refractive index of 1.4510 and a s ec'fic ravit of 1.074. (0 0R) p 1 g y or a urethane EXAMPLE 4 o it To a flask there was added 84.2 g. of (-0 NHR) radical. Of these, the acyloxy and urethane radicals are (CH Si[OSi(CH [OSi(CH )H] OSi(CH preferred with the latter being the most preferred. Specific illustrative examples of the G group are 188.7 g. of

0 0 o 0 0 -ohen., -oh0tHi, whom, -0ho0m, -ohooin.

OH2=CHCHflO CQHOHOECH;

45.4 g. of n-propanol, 45.4 g. of toluene and 0.6 cc. of a and dNHo,H, 2% platinum (as chloroplatinic acid) solution in iso- The values of th var-OHS subscri ts a, b c d e and propanol. The foregoing mixture was heated at to f have been Set abgve and degne the i i of the 60 C. for about 30 minutes, filtered, and then stripped to difiering portions of the copolymers so that the advantages at 6 of mercury Pressure' The Product and objects of this invention can be achieved.

Now in order that those skilled in the art may better understand how the present invention can be practiced, the following examples are given by way of illustration and not by way of limitation.

All parts and percents referred to herein are y weight had a viscosity of 216 cs., a refractive index of 1.4480 and all viscosities measured at 25 C. unless otherwise and a specific gravity f 1,073, specified.

O 65 (CH;) Si[OSi (CHmMOSi (CH3) CHICHZCHKOClHOHO CHahOSiMea EXAMPLE 1 EXAMPLE 5 To a flask there was added 77.1 g. of Wh th I d d en e si oxanes an unsaturate compounds speci- (CH3)3S1[0S1(CH3)2]7[OS1(CH3)H]3OS1(CH3)3 fied below are reacted following the procedure of the gfof v y 75 preceding examples, the indicated product is obtained.

A mixture of 193.3 parts of a sucrose polyether, 76.3 Scale was used in the evaluationsparts of monofluorotrichloromethane, 3.1 parts of a 33% solution of triethylenediamine in dipropylene glycol and Value Cells Flow lines 2.1 parts of dimethylaminoethanol was placed in a one 10 quart Dixie cup. There was then added 2.0 parts of the 9 fine siloxane additive of this invention followed by the addition of crude toluene diisocyanate in an amount equivalent to 105% of the hydroxyl groups in the polyether (i.e., a 5% excess of isocyanate was added). The above ingredients were hand-mixed on a Hamilton Beach malttype mixer mounted on a drill press stand. Mixing time was five seconds at 2200 r.p.m.

In order to evaluate the characteristics of the rigid The following siloxane additives were employed 1n the urethane foams prepared in accordance with this invenabove formulatlon and Process to make ngld urethane tion, immediately after preparation (supra) they were foams' poured into an L-shaped mold having a 10% inch by 15 inch base and a 10 /2 inch by 24 inch vertical leg, both (A) The sfloxane of Example 2 base and leg being 1 inch deep. The mold was lined with (B) The siloxane of Example 3 a polytetrafluoroethylene coated fabric sheet and coated 0 Th f 1 with a thin layer of paste wax for release. At the forward e oxaneo Examp e 4 part of the mold is a three inch hinged flap where the foam (D) CH3 0 ingredients were poured. The ingredients were poured into CH Osi C O C C H l 0 the mold for aperiod of five seconds, the flap immediately Hmm 1( Hmw 2 0120 NH zHfihoSlwHa) closed and clamped, and the foams allowed to rise and cure 0 for P P ten minutes before releasillg- The quart F Hm iw iwmnhmoi( Hz)3(ocimmoi maczmhos am containing the excess foam were weighed after pouring to insure that all panels were of equal charge or quantity. (F)

In the L-shaped mold, the foam must travel horizontal- (CH Si[()Si(CH [OSi(GH (OC H4) O6lNHC H hOSi (C1193 1y along the base of the mold, round a 90 corner, and then travel vertically. The narrowness of the mold and (G) CH3 0 the cornering place shearing eifects on the rising foam (CHi) Si[0Si(OH )z]za[OS!i(CH2)a(O 02110120dNrrclrrslwosiwrrm mass which simulate cast-in-place use conditions. After the foam had cured, it was removed from the mold and (H) E 0 cut in half vertically. First the height to which the foam a)a l a)zlu[0si( H2)s( 01110140 CHdsOSK m rose was measured. One-half was then cut horizontally (D CH 0 3 /2 inches above the base. At this point maximum flow a 1 lines (striations) are observed and are rated. The size l a)2]1[0Si(CH2)a( 1 014 s]a0Si(CH 7 In the table below the evaluations of the siloxane additives above is set forth.

Height Flow Additive (inches) Cells lines EXAMPLE 7 in which formulae R is a hydrocarbon radical free of aliphatic unsaturation and contains from 1 to 10 carbon atoms, A is a radical of the structure --D(OC H );G wherein D is an alkylene radical, G is a radical wherein R is as defined above, f has an average value from 9-30, a has an average value from to l, b has an average value from 6 to 192, c has an average value from 0 to 30, d has an average value from 3 to 30, and

8 e has an average value from 1 to 30, the ratio of the OSi(CH units to the OSi(CH )A and/or OSi(CH A units in the siloxane being in the range of 2:1 to 6:1. 2. The method of claim 1 wherein the compound has the Formula 3.

3. The method of claim 2 wherein A is a radical of the structure 0 2)a(OCzH|)0 3NHR 4. The method of claim 3 wherein f is about 12 and R is C2H5.

5. The method of claim 1 wherein the compound has a the Formula 4.

6. The method of claim 5 wherein A is a radical of the structure 7. The method of claim 6 wherein f is about 12 and R is C2H5- References Cited UNITED STATES PATENTS 3,194,773 7/1965 Hostettler 2602.5 3,222,357 12/ 1965 Wismer et al 260209 3,298,919 1/1967 Bishop et a1. 167-85 3,398,104 8/1968 Haluska 26025 3,402,192 9/1968 Haluska 260448.2 3,404,168 10/ 1968 Simmler et al 2604482 FOREIGN PATENTS 695,633 10/1964 Canada 2602.5 AH

OTHER REFERENCES Japanese patent specification publication No. 39/24731, pp. 1-6 (1964).

' Japanese patent specification publication No. 40/ 12190, pp. 13-20 (1965).

Dutch patent specification publication No. 6408328, pp. l11 and Figs 1- 13(1965).

DONALD E. CZAIA, Primary Examiner M. I. MARQUIS, Assistant Examiner US. Cl. X.R.

26046.5 E, 46.5 UA, 448.2 N; 264338 

